SunBear_InstallManual-RevB.pdf

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Sun Bear Installation Manual Document Number 9910019 Rev B February 2014

Sun Bear Installation Manual Document Number 9910019 Rev B 2

Revision History

Rev ECO # Date Description of Changes Approved By

A C00242 07-MAR-13 INITIAL RELEASE JA

B C00300 07-FEB-14 Updated order of assembly and safety information. CA


Table of Contents Introduction ............................................................................................................................. 4

Document Objective ................................................................................................................ 4

Safety Overview ....................................................................................................................... 5

Sun Bear Components .............................................................................................................. 6

Required Tools ......................................................................................................................... 7

Step 1. Survey Installation Site and Install Foundations ...................................................... 8 Step 2. Attach Struts to Foundations ................................................................................... 8 Step 3. Prepare the Preassembled Frame for Modules ..................................................... 11 Step 4: Install Three Rows of Modules on the Preassembled Frame ................................ 15 Step 8: Lift Frame into Place and Attach Struts ................................................................. 19 Step 9. Install the Last Row of Modules ............................................................................. 20 Step 6: Adjust Struts to Change Frame Position and Tilt ................................................... 24 Step 7. Ground the System ................................................................................................. 25

Technical Support ................................................................................................................... 26


Introduction The Sun Bear fixed-tilt ground mount system (Sun Bear) is designed to install faster than any other system on the market as of the date of this Installation Manual. Its four-component design includes a preassembled frame and in-field adjustability, for an unmatched combination of simplicity and flexibility. There are zero loose fasteners and all components are preassembled to speed construction and eliminate costly onsite drilling, cutting, or welding. Sun Bear features include:

Accelerated construction time: Designed to be the fastest system to install in the market. Only four major components and zero loose fasteners.

Adjustability: Strut components have integrated turnbuckles to allow in-field adjustments to racking without drilling or cutting.

Interchangeable foundation: Above-the-ground racking design does not change. The racking is independent from the foundation choice.

Material-saving truss design: Strut components carry only tension or compression loads making them light weight and structurally efficient.

Preassembled frames with telescoping rafters: Reduces overall height and width for easier shipping yet deploy in seconds in the field.

The Sun Bear system has been extensively tested, undergoing individual component finite element analysis, computational fluid dynamics modeling, static load modeling, and wind tunnel testing. All testing has been independently conducted by third parties and provided to PanelClaw, Inc. (PanelClaw).

Document Objective This installation manual has been put together to assist in the proper steps required to build a Sun Bear ground mount system array. The manual covers a best-practice order of assembly for the construction of the ground mount array and contains detailed notes and tips for a successful assembly.


Safety Overview The Sun Bear system architecture and structural engineering is based on a space frame, a truss-like rigid structure constructed from interlocking struts in a geometric pattern. Like the truss, a space frame is strong because of the inherent rigidity of the triangle; flexing loads (bending moments) are transmitted as tension and compression loads along the length of each strut. These structures are used in bridges and skyscrapers for their strength, efficiency, and reliability. It is important to know however that each member (strut) in a truss design is required for the system to stay erect safely. No single Strut in the Sun Bear system may be removed from the truss without the system becoming unstable. This must be kept in mind when constructing Sun Bear and when following the installation procedures.

Note the appearance of the within this installation manual. It serves as a reminder to the unique behavior of a truss system and the safety precautions that must be followed. PRIOR TO INSTALLATION, READ THE SAFETY PROVISIONS ATTACHED ON APPENDIX A AND REVIEW THE INSTALLATION MANUAL IN ITS ENTIRETY.


(x 3) (x 7)

Sun Bear Components Foundation Strut

Frame Claw

Foundation (1) South; (2) North. North foundations are shared with adjacent tables. 1a. Built-in keyhole Keyhole cutouts to attach Struts. Strut (2) South (red); (2) North-South (green); (2) North (blue); (1) Cross (black). 2a. Color code strap Red, Green, Blue, and Black.

2b. Jam nut Built-in -10 jam nut.

2c. -13 fastener Built-in fastener and spherical seat.

Frame Pre-assembled. Available in 4x4 (60-cell modules) and 4x3 (72-cell modules). 3a. In-board rafter Component of frame to support modules. 3b. Out-board rafter Telescoping rafter. Arrives in stowed position. 3c. Purlin Includes (8) eight keyhole cutouts for Strut attachment. Claw Includes two pre-installed fasteners, 5/6-18 x 1.5L and 5/16-18x2.5L. 4a. Mid Claw Secures modules to frame between module rows. Shared between two modules. 4b. End Claw Secures exterior module to frame. Wire Management Hook Secures wire runs to frame.

Table 1 Sun Bear Component List


Required Tools

Tools Required

3/4 ratcheting wrench

3/4 deep well socket

1/4 drive socket (Allen head), mininum length of 1-7/8

1-1/8 wrench or sufficient adjustable wrench

Calibrated torque wrench (or equivalent tool)

Other items 25 tape measure

Project drawing

Note: For your convenience, a complete Sun Bear tool kit and Rigging kit is available for purchase from PanelClaw.

Suggested Equipment for material handling

8 forklift extensions

Forklift hook plate

Rough terrain forklift

Skid Steer forklift

(4) 10 two-ton straps and J hooks for lifting frame bundles (one frame bundle contains seven frames). The frame bundle weight is 2,100 lb.


Step 1. Survey Installation Site and Install Foundations

1. Mark each foundation installation location using site surveying equipment and the provided project drawing (Figure 26, on page 24) as a guide.

2. Reference the project drawing (Figure 26, on page 24) to determine each arrays nominal foundation stick up height. Install the foundations at each marked location using foundation installation equipment.

NOTE: If the array is being built on a slope ensure that the south foundation elevation is equal to the average elevation between the two north foundations for that frame.

Step 2. Attach Struts to Foundations

1. Identify each Strut using its color code strap (Figure 1) and match it to its compatible foundation according to the Strut Arrangement diagram (Figure 2).

NOTE: Struts with double color code straps are to be used only with the smaller, two column frames. Reference the project layout to determine which Strut types are needed.

Figure 1 Color Code Strap on Strut

2. Place Struts with strap and jam nut (Figure 1) closest to its matching foundation.

NOTE: Incorrectly matching the Struts to the foundation will result in an inaccurately positioned Frame.

Figure 2 Strut Arrangement


3. Attach all Struts but the Cross Strut (black) into the keyhole on their respective foundation (Figure 3). Prepare the Cross Strut by placing it near the North-West foundation and with its color strap and jam nut end next to the foundation.

NOTE: Cross Strut will be attached to foundation in Step 3.

4. Struts are attached to the keyhole on the south side of the keyhole so that the fastener passes through the hole in a south to north direction.

5. Make sure the spherical seat is properly seated in the lower keyhole opening (Figure 4). A self-locking feature will prevent the Struts from accidentally sliding out of the keyholes during assembly.

WARNING: Failure to properly seat the spherical seats in the foundation or the Frame will result in an unstable structure.

Figure 3 Strut to Keyhole Alignment


Figure 4 Properly Seated Spherical Seat

6. Follow the Strut-to-connection installation sequence (Figure 5). The Strut fasteners should be torqued up to 5ft-lb [6.8N-m] at this time to ensure the spherical seat remains in position

NOTE: These connections will undergo final torqueing at a later step.

Figure 5 Strut-to-Connection Installation Sequence


Step 3. Prepare the Preassembled Frame for Modules

1. Place (4) four 2x4x12L wood spacer blocks on the ground in front of the southern purlin

of the Frame (Figure 6). NOTE: The spacer blocks are not required but facilitate easier sliding of the Frame when attaching Struts.

Figure 6 Frame Placed at Installation Location

2. Unload Frame from delivery equipment and rest the southern purlin on top of the spacer blocks ensuring that the Frame is placed with the rafter opening face up. NOTE: It is acceptable for the northern part of the Frame to rest on top of the Struts, or on the ground.

3. Install an End Claw on the northern edge of each rafter while the Frame is on the ground and easier to access. Position the End Claw flush with the outer edge of the rafter block (Figure 7). Tighten the End Claws rafter fastener to a torque of 9ft-lb [12.2 N-m] using the Allen head drive socket.

4. Repeat for all of the End Claws on the northern rafters. NOTE: Only the northern rafter End Claws should be installed at this time. Installation of additional Claws will result in having to remove them to ensure proper fitment to the module.


Figure 7 End Claw Installation on Northern Rafters

NOTE: It may be necessary to rotate the rafter block slightly to square the block with the rafter edge after torqueing. This may be done by placing the Allen head socket into the extrusion of the rafter block and rotating.

5. With two crew members, lift the Frame by the north edge to shoulder height.

6. With the north end of the Frame raised, attach the North-South Struts (green) to the

Frames south purlin. Move the Frame as needed to align the Struts to the Frames keyhole.

WARNING: Move the Frame as needed to align the Struts. Do not attempt to adjust the length of Struts in order to reach the Frames keyhole or else the ability to make adjustments later will not be possible.

7. Secure the North-South Struts (green) to the Frame using the same installation steps that were used to attach the Struts to the foundations.

8. Figure 8 identifies the correct locations for North-South Strut installation to the Frame.

9. Tighten these connections to a torque of 5ft-lb [6.8N-m]. NOTE: These connections will undergo final torqueing at a later step.


Figure 8 North-South Strut Connection Locations

10. Attach the North Struts (blue) to the Frames north purlin (Figure 9). Secure the North Struts to the Frame using the same installation steps that were used to attach the Struts to the foundations.

11. Tighten these connections to a torque of 5ft-lb [6.8N-m].

12. Attach Cross Strut (black) to the Frames north purlin (Figure 9). Secure the Cross Strut to the Frame using the same installation steps that were used to attach the Struts to the foundations.

13. Attach Cross Strut to its foundation and shift the Frame east-west as needed to make the proper connection.

WARNING: The Cross Strut (black color code strap) must be attached to foundation with the slot opening facing up to reduce force on the Strut.


14. Tighten the connection to a torque of 5ft-lb [6.8N-m]. NOTE: These connections will undergo final torqueing at a later step.

WARNING: Do not stand on Struts.

Figure 9 North Strut and Cross Strut Connection Locations

15. The prepared Frame will resemble Figure 10 below once complete. The South Struts (red)

will be attached at a later step.

Figure 10 Partially Erected Frame


Step 4: Install Three Rows of Modules on the Preassembled Frame

1. Populate the Frame with modules starting from the middle column of the Frame. Place the first module on the End Claw rafter block (Figure 11). Do not tighten the Claws module fastener at this time.

Figure 11 Add Module to End Claw

2. Adjust the module placement east-west so that the module is centered on the two rafters (Figure 12).

Figure 12 Module Placement

3. Note which side the module junction box is located. When adding the next module, make sure all junction boxes are positioned on the same side.


4. With the module aligned, tighten the module fastener on the End Claw to a torque of 13 ft-lb [17.6 N-m] using a Allen head drive socket.

5. Push the module up to deploy the rafters and position the module into the final position (Figure 13). When in the deployed position, the locking tab will engage with the locking slot and the rafter will click.

NOTE: To prevent over extension of the rafters it is helpful to place slight pressure using your thumb on the locking tab to ensure that it engages with the locking slot on the rafter being deployed.

Figure 13 Module Placement

6. Place the Mid Claws on the lower side of the module by inserting the Claw blocks into the rafter and then sliding toward the module. Lift module onto the Mid Claw rafter block (Figure 14) and (Figure 15).

TIP: For a consistent look, make sure the orientation of all the clamps are the same on each Mid Claw.


Figure 14 Add Mid Claw

Figure 15 Mid Claw Placement

7. Push the Claws rafter block against the module Frame to ensure that no gap is introduced between rows of modules.

8. Tighten the Mid Claws rafter fastener (Figure 16) to 9 ft-lb [12.2 N-m] using a Allen head drive socket. Do not tighten the Claws module fasteners to the module at this time.

Figure 16 Tighten Mid Claw


9. Place the second module in this column onto the Mid Claw rafter blocks. Push the module Frame up against the rafter block so that no gaps are introduced between rows of modules.

10. Ensure that the modules are aligned vertically.

11. Insert the next Mid Claws for this module (Figure 14) and (Figure 15).

TIP: A X 10 EMT conduit may be used as a guide stick to align modules and space columns of modules correctly. A 1 X 2 X 10 strip of wood may also be used to guide module placement.

12. Tighten the Mid Claws between the two modules to 13 ft-lb [17.6 N-m] using a Allen head drive socket (Figure 17).

Figure 17 Tightening Mid Claws to Modules

13. Tighten the Mid Claws rafter fastener on the exposed side of the second module to 9 ft-lb [12.2 N-m] using a Allen head drive socket (Figure 16).

14. Place the third module in this column on the Mid Claw rafter blocks. Push the module Frame up against the rafter block so that no gaps are introduced between rows of modules.

15. Ensure that the modules are aligned vertically.

16. Place the next Mid Claws for this module (Figure 14) and (Figure 15).


WARNING: Do not tighten the last Mid Claw rafter fasteners as this will secure the south rafter and prevent it from telescoping out once the Frame is fully erected.


18. Repeat these to install the remaining columns of modules leaving a 1 space between each column (Figure 18).

Figure 18 Install Remaining Columns of Modules

Step 8: Lift Frame into Place and Attach Struts

This step may be accomplished with many approaches however only the skid steer method is described below.

1. Position the skid steer forks in line with the south foundation (Figure 19).

2. Insert forks under the Frames purlin while allowing clearance to the South Struts.

3. When lifting the assembly the purlin will slide on the forks. Ensure that there is enough sliding room on the forks so that the load does not come off.


Figure 19 Designated Lifting Area

4. Lift the Frame to the height indicated on the provided drawings. Once at this height the South Struts can be connected to the Sun Bear Frame.

WARNING: Do not go under the Frame table while elevated until all connections have been properly torqued.

TIP: To prevent going under the Frame before it is properly torqued, use your foot to hook the South Strut and drag it from under the Frame and within reach.

5. Torque all Strut connections starting with the connections to the Frame followed by the connections to the foundations. All Strut fasteners should be torqued to 50ft-lb [67.8N-m] before removing the forklift support.

6. Do not install the remaining row of modules until the Frame fasteners are properly torqued.

Step 9. Install the Last Row of Modules

Gloves should be worn during this step to avoid injury when coming in contact with the sharp metal edges.


1. Locate the tab on the Frames in-board rafter (Figure 20).

2. Apply pressure to the tab while pulling the outer rafter until the tab locks in place (Figure 20). The rafter is now fully extended.

3. Repeat this step for the remaining stowed rafters to deploy the entire Frame.

NOTE: Do not pull the rafter out beyond the locked position.

Figure 20 Extending the Rafter

4. Install the Mid Claws under the third row of modules by inserting the Mid Claw block into the rafter and then sliding toward the module. Lift module onto the Mid Claw rafter block (Figure 21) and (Figure 22).

Figure 21 Add Mid Claw


Figure 22 Mid Claw Placement

5. Tighten the Claws rafter fastener on the Mid Claw to 9 ft-lb [12.2 N-m] using a Allen head drive socket (Figure 23). Do not tighten the module fastener to the module at this time.

Figure 23 Tighten Mid Claw

6. Place the last module in this column on the Mid Claw rafter block.



Figure 24 Tightening Mid Claws to Modules

4. Place the End Claw under the module by inserting the End Claw block into the rafter and then sliding toward the module. Lift module onto the End Claw rafter block (Figure 25).

5. Tighten the End Claws rafter fastener to a torque of 9ft-lb [12.2 N-m] using a Allen head drive socket.

6. Repeat for the second End Claw required for that module being installed.

7. Torque the Claws module fasteners to 13 ft-lb [17.6 N-m] using a Allen head drive.

8. Repeat for remaining modules.

Figure 25 Installation of End Claws to Final Row of Modules


NOTE: End Claws are utilized to attach the outer edge of the module at the top and bottom of each column. End Claws will be flush with the rafter edge on the top, but may or may not result in a flush installation on the bottom of each column (Figure 25).

Step 6: Adjust Struts to Change Frame Position and Tilt

All Struts are designed as turnbuckles, with -10 threaded ends (one end has right-hand threads and the other has left-hand threads). Rotating the Strut tubes in one direction extends the Strut length, and rotating them in the opposite direction shortens the length. Struts will extend/shorten by 1 [25 mm] for every (5) five turnbuckle rotations. All Struts come out of the factory in nominal position. Maximum adjustment is +/- 6 from nominal.

1. Reference the provided project drawing to determine the nominal dimensions and

geometry of the assembled structure (Figure 26).

Figure 26 Provided Drawings

2. If adjustment is required, follow (Figure 27) for a description on how to extend and/or shorten Struts depending on the Strut orientation.

3. Loosen the jam nut, nearest the snout (Figure 27), on each Strut with a 1-1/8 wrench before adjusting Strut lengths. Turn the corresponding Struts in order to adjust the Frame position and tilt.

NOTE: In some configurations the Struts may be equipped with multiple jam nuts. In these instances, only the jam nut nearest to the snout needs to be loosened for Strut adjustment.


Figure 27 Strut Adjustment

4. Tighten the jam nut finger tight against the snout of the Strut and tighten an additional

quarter turn using a 1-1/8 wrench to prevent any further Strut adjustment.

Step 7. Ground the System The Sun Bear system and all of its components have been certified by Intertek (ETL) to ground modules in accordance with UL Subject 2703. The Claw to module and Claw to rafter connections, when properly torqued per the previous steps, are capable of bonding to and grounding all UL 1703 listed modules which fall within a series of construction criteria. The module can be constructed of single or double walled anodized aluminum Frame with a height range of 1.18-2.0 [30mm-50mm] and nominal wall thickness of 1/16-1/8 [1.5mm-3.0mm]. Systems up to 1000VDC can be built using PV modules with a maximum series fuse rating of 30A. In addition to the module being bonded to the Frame via the Claw assembly, all other system connections have been evaluated as a bonded equipment ground path through the Frame, Struts, and foundation connections. This allows for the use of a single ground lug per continuous E-W array. PanelClaw provides four symmetric predrilled grounding locations per Frame (Figure 28) for the installation of a UL 467 approved grounding device. PanelClaw has evaluated the Sun Bear system with the TYCO SOLARLOCK grounding bolt, BURNDY CL-50-1TN direct burial lay-in lug, and ILSCO GBL-4DBT direct burial lay-in lug with a #6 AWG Copper EGC.


Figure 28 System Grounding

When using a TYCO SOLARLOCK grounding bolt, insert the threaded post of the bolt through one of the predrilled grounding locations on the Sun Bear Frame and tighten the TYCO keps nut to 2.1 ft-lb [2.82 N-m]. Install a single #6 AWG copper ground conductor into the open wire binding post of the bolt and tighten to 3.8 ft-lb [5.08 N-m]. When using a BURNDY CL-50-1TN or ILSCO GBL-4DBT direct burial lay-in lug, install it at one of the predrilled grounding locations on the Sun Bear Frame using a stainless steel 10-32x1 machine screw (McMaster Carr PN: 90316A833), stainless steel #10 flat washer between lug and Frame (McMaster Carr PN: 92141A011), and stainless steel 10-32 keps nut (McMaster Carr PN: 96278A411) tightened to 6 ft-lb [8 N-m]. Install a single #6 AWG copper ground conductor into the slotted screw connection of the lug and tighten to 2.9 ft-lbs [4 N-m]. All wiring and grounding must be done in accordance with local and national codes in accordance with the National Electrical Code (NEC) ANSI/NFPA 70 (US only) in order to reduce risk of fire and electrical shock.

Technical Support To contact PanelClaw Customer Technical Support, call +1 978.688.4900 or email [email protected].


Appendix A: Safety General Installation Safety with PanelClaw Products: Safety is an essential part of every photovoltaic (PV) installation and every construction site. It is imperative to plan ahead for any safety concerns and hazards to promote safe work practices during installation. This section does not claim to address or support all safety concerns that may arise during the installation of PanelClaw mounting systems or any other aspect of the work being performed. Before beginning work, installers should refer to all local and federal safety, health, and regulatory requirements to assure compliance. Refer to OSHA Part 1926 and its related Subparts for federal construction related regulations and standards. The subsections below outline some of the obvious / major hazards that could exist during the installation of PanelClaw products, and are divided to bring a level of clarity to such hazards. Some sections do not apply to all PanelClaw product lines and such exclusions are noted within each section. Electrical Hazards: PanelClaw products are purely mechanical and do not contain any electrically live parts. When a photovoltaic module is exposed to sunlight it is electrically live and cannot be turned off. As soon as modules are installed using a PanelClaw system, an electrical shock hazard is present. All personnel on site should coordinate to ensure that such electrical hazards are clearly communicated. It is advised, at a minimum, that all personnel utilize caution and proper Personal Protective Equipment as outlined in that section. Only electrically qualified personnel should perform PV module installation. Refer to OSHA Part 1926 Subpart K Electrical and NFPA 70E for additional information. Trip Hazards: All PanelClaw arrays have elevated components that are installed above grade or above a roof surface. Such hazards should be identified and caution should be taken to avoid tripping over such components. Refer to the Fall Hazards section specifically if working with the Grizzly Bear, Polar Bear, and Sun Bear product lines. Make sure to pick up and not drag your feet when working on site, and always pay attention to your path of movement to note any obstructions that could create a trip hazard. Lifting Hazards: The PanelClaw installation process involves lifting of heavy items that could lead to personal injury and damage to property. All personnel should be trained in the proper procedures for manually lifting. Evaluate an objects size and weight prior to lifting, and follow these general guidelines for lifting:

1. Assess the lift and know the object weight. 2. Bend at the knees and get a good grip. 3. Keep back straight and lift straight up with legs without twisting. It is important to lift with

the legs and not the back.


4. If an object is too large or heavy, ask for help and do not attempt to lift by yourself. In the case that mechanical assistance (e.g. crane, forklift, etc.) is required to complete the lifting operations, all machine operators of such devices should be licensed and trained.

Material Handling: All PanelClaw parts and components are made of aluminum and steel alloys and utilize stainless steel assembly hardware. These materials are considered non-toxic and require no special handling procedures. Metal components may have sharp edges, so be sure to handle with care and utilize proper personal protection equipment, especially gloves, during handling. Refer to OSHA Part 1926 Subpart H Materials Handling, Storage, Use, and Disposal for additional information. Personal Protective Equipment (PPE): All personnel should utilize and implement proper PPE per OSHA requirements. Refer to OSHA requirements for proper use and implementation of PPE. The following items are suggested as a minimum to avoid injury based on the installation procedure outlined in this manual:

1. Appropriate work clothing 2. Electrically insulated hard hat 3. Protective eyewear 4. EH rated safety boots 5. Gloves 6. High-visibility safety vest 7. Hearing protection

If any PPE appears to be defective, stop the use of such equipment immediately, and ensure it is replaced before work continues. Refer to OSHA Part 1926 Subpart E Personal Protective and Life Saving Equipment for additional information. Hand and Power Tools: Access to all hand and power tools should be regulated and controlled at all times on site to prevent improper use and related injuries. When not in use, all equipment should be stored in a secured location. Only personnel who have been properly trained in the safe operation of any potentially dangerous tool should be allowed access. All required tools to perform the installation of PanelClaw racking are outlined in the installation procedure. All tools should be inspected daily and before use by the operator. If any tool appears to be defective, stop the use of such equipment immediately, and ensure it is replaced before work continues. Electrical power tools should follow proper lock-out tag-out procedures per OSHA requirements. Refer to OSHA Part 1926 Subpart I Tools Hand and Power for additional information.

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SunBear_InstallManual-RevB.pdf